Chewing gums and process for the manufacture thereof

ABSTRACT

Disclosed are small pellets or “mini-dragées” with a core constituted by a gum base which is flavored and possibly sweetened with high-intensity sweeteners, and formulated without the sugars or polyols conventionally used in the manufacture of traditional chewing gums.

The present invention relates to small pellets or “mini-dragées” with acore consisting of a gum base which is flavored and possibly sweetenedwith high-intensity sweeteners, and formulated without the sugars orpolyols conventionally used in the manufacture of traditional chewinggums.

Gum base, one of the main, most complex ingredients in chewing gum, canbe made by mixing ingredients belonging to the following classes:vegetable or synthetic gums, resins, waxes, emulsifiers., processingaids, fillers and antioxidants.

The gums supply the cohesive structure of the gum base; this structuremay vary, depending on the specific gum or mixture of gums used, whichmay be synthetic or vegetable gums. The synthetic gums typically usedare polyisobutylene, isobutylene-isoprene copolymer, and others. Thevegetable gums traditionally used to make the gum base are chicle,jelutong, etc.

Various types of resins may be used to modify the hardness of the gumbase, as well as having a cohesive effect on it. The main resins used,listed by way of example but not of limitation, are terpene resins,rosin esters and polyvinyl acetate.

Waxes, emulsifiers and processing aids are normally used to modify thetexture and plasticity of the gum base. This large class of ingredientsincludes the following ones, listed by way of example but not oflimitation: hydrogenated vegetable oils (such as palm, cotton and soyoils), microcrystalline waxes and refined and synthetic paraffin waxes,beeswax,. candelilla and carnauba wax, acetic esters, glycerolmonostearates and their acetic esters, glycerol and others.

Fillers also have an important influence on the mechanical andstructural properties of the gum base, as well as being useful assupports or gliding agents. The fillers most often used are calciumcarbonate, magnesium carbonate and talc.

In addition to the above-mentioned classes of ingredients, otheringredients may also be added to the gum base, such as antioxidants,designed to preserve it from oxidative effects which could adverselyaffect its flavor or reduce its durability.

A typical gum base composition is set out below: Ingredient Example no.1 Example no. 2 Synthetic gums 21.7% 9.8% Vegetable gums — — Resins35.0% 41.7% Waxes and hydrogenated vegetable 21.4% 3.3% oils Emulsifiersand processing aids 6.3% 2.9% Fillers 15.5% 42.2% Antioxidants 0.1% 0.1%TOTAL 100.0% 100.0%

Most chewing gums now available are presented in the form of sticks orpellets. Chewing gum pellets comprise a core of gum base mixed withother components (flavorings, polyols and/or sugars, plasticisers, etc.)with a coating consisting of sugar or polyols such as maltitol, xylitoland the like.

The traditional pellets are quite large. Spherical or spheroidal pelletsmay have a diameter of 10-15 mm, while gum in the form of rectangulartablets may have dimensions of approx. 10×20 mm or even more.

The size of chewing gum pellets, which are becoming more popular on themarket than sticks, is partly due to technical requirements associatedwith the formulation of the gum; in order to produce the characteristicof chewability, a polyol matrix must be added to the gum base in theproportion of approximately twice the weight of the gum base. However,for the reasons stated above, if conventional production methods wereapplied to the manufacture of small pellets the results would beunacceptable, since the absolute amount of gum base would be too low,and the composition would not be sufficiently chewable.

On the other hand, the gum base alone, without the addition of a polyolmatrix, enables small pellets of acceptable chewability to be produced.However, a flavored, sweetened gum base of this kind has plasticitycharacteristics that make rolling into sticks or pellet cores difficult,if not impossible; moreover, the use of ordinary rolling mills preventsspheroidal products from being made.

Chewing gum in the shape of small spheroidal pellets would be desirablefor various reasons: for example, consumers could modify the amount ofgum chewed as required by using a suitable number of small pellets,possibly at different times (e.g. in sequence). In addition, a smallspheroidal pellet would be liked better by children, as chewing a masswith a volume exceeding a given threshold can be uncomfortable andunsatisfactory for them.

Italian patent no. 1180176, in the name of Gum Base Co. SpA, relates toa non-cariogenic, low-calorie gum base composition with no sugar matrix,characterized by a specific composition of the various components of thegum base such as polyisobutylene elastomers, vegetable or animal oils,vinyl polymers, resins, natural gums, waxes, and mono- and di-glyceridesof fatty acids. This gum base, added with flavorings, high-intensitysweeteners and glycerin, allows the manufacture of chewing gum with goodplasticity characteristics and a very high gum base content, despite theabsence of a sugar or polyol matrix. The same patent relates to themanufacture of sticks by rolling the gum base composition, but not tothe production of pellets.

Flavored gum base compositions are disclosed in U.S. Pat. No. 6,264,999,which however always refers to the use of erythritol as bulk sweetener.WO 96/08157 describes a process for the extrusion of gum base which mayalso contain flavorings.

EP 732055 discloses a continuous process for the preparation of chewinggums without separate preparation of the gum base. The specific examplesin this document also involve the use of sugars or polyols.

Finally, U.S. Pat. No. 6,017,565 describes a continuous process similarto that disclosed in EP 732055, and illustrates in detail themanufacture of chewing gums in pellet form. The use of polyols, inparticular sorbitol and mannitol, is also described in this case.

The prior art therefore does not contain teachings or suggestions usefulfor the preparation of small size gum base cores without sugar or polyolmatrices, which contain flavorings and high-intensity sweeteners.

It has now been found that small pellets or mini-dragées containing aspheroidal core with a diameter below 10 mm, preferably a diameter below7 mm, and even more preferably a diameter below or equal to 5 mm,constituted by a flavored and possibly sweetened gum base, can beobtained with a process that comprises:

a) mixing the gum base components in a mixer at the temperaturesnormally used;

b) cooling the mixture obtained in a) to a temperature of between 60 and90° C., possibly in a second mixer, and addition of flavorings andhigh-intensity sweeteners under stirring;

c) extruding the mass obtained in b) in a heated extruder throughsmall-diameter holes;

d) forming the cores by cutting with rotating blades immersed in a waterstream at a temperature of between 10 and 20° C.;

e) separating, drying and talcing or dusting the spheroidal coresobtained in d);

f) possibly, coating-the spheroidal cores.

The production method of the present invention not only allows theproduction of mini-dragées as described above, but also eliminates theusual step of mixing the gum base with the other ingredients (such assugar or sorbitol), and above all the rolling step.

Various types of gum base can be used in accordance with the invention,provided that they possess some essential properties such as notsticking to the teeth and are pleasant to chew as a result of the simpleaddition of flavorings and possibly high-intensity sweeteners. It hasbeen found that the gum bases which guarantee absence of stickiness andthe best chewing characteristics are preferably obtained withformulations included in the following example:

-   -   8 to 15% of an elastomer selected from the group comprising        polyisobutylene and isobutylene-isoprene copolymer    -   0 to 8% of a natural gum    -   8 to 20% of resins selected from the group of vegetable and        synthetic resin esters    -   8 to 20% of polyvinyl acetate    -   8 to 25% of hydrogenated or partly hydrogenated vegetable or        animal oils    -   3 to 10% of waxes selected from the group comprising vegetable        waxes and waxes derived from petroleum or obtained synthetically    -   2 to 10% of emulsifiers and processing aids, more specifically        glycerol monostearate, acetylated monoglycerides, lecithins and        triacetin    -   10 to 45% of inert mineral fillers    -   up to 0.1% of antioxidants.

The flavorings used in accordance with the invention can be selectedfrom a wide range; typical examples include essential oils (peppermintoil, citrus fruit oil, fruit essence, etc.) or synthetic flavorings.

Aspartame, acesulfame K, thaumatin, neo-hesperidin dihydrochalcone,cyclamate, sodium saccharine, alitame, stevioside, glycyrrhizine,neotame, sucralose and the like, possibly in mixtures thereof, can beused as high-intensity sweeteners.

Acesulfame K and neo-hesperidin DC in particular are preferred for theirheat stability.

It has surprisingly been found that the use of neo-hesperidin DC, ashigh-intensity sweetener in combination with acesulfame K, in amountsranging from 10 ppm up to 400 ppm, gives to the coated spheroidalpellet, after dissolution of the coating polyalcohol, a surprisinglylong-lasting release of the taste from the residual gum. This is due tothe persistence of the sweet taste in the residual gum during chewing,which allows the palate a long-lasting perception of the flavorings aswell.

This persistence of the sweet taste. (which is unique among the otherhigh-intensity sweeteners) derives from the optimal partition ofneo-hesperidin between saliva and base gum polymers, which provides alonger-lasting permanence and therefore a longer-lasting release ofneo-hesperidin in the gum base.

If desired, the sweetener and/or flavorings can be encapsulated by knowntechniques in order to stabilize them.

Colorings or other additives acting as plasticisers, suitable forfoodstuffs, such as glycerol, sorbitol syrup and the like, may also beadded to the gum base.

One of the specific embodiments of the process for preparation of thepellets in accordance with the invention comprises a first step in whichall starting materials constituting an ordinary gum base (elastomers,polymers, fillers, hydrogenated oils, waxes and everything else needed)are added in a double-Z mixer. Mixing takes place with heating at thetemperatures normally used until a homogenous, liquid, but viscous massis obtained. This step is identical to the process used for an ordinarygum base, and can be performed with any suitable mixer, including acontinuous mixer or extruder.

If continuous extruders are used, the flavoring can be added in the lastpart of the extruder with no need for the cooling and mixing stepdescribed below, and the resulting product can directly feed thespheroidal core formation unit.

If double-Z or non-continuous mixers are used, the mixed mass can betransferred while still hot to a second unheated or water-cooled mixeruntil it reaches a temperature of approx. 80° C. The flavoring, andpossibly high-intensity sweetener, can then be added. It is important touse a mixer that minimizes mixing time with the flavoring to avoid lossof flavoring, such as a screw mixer with plough blades. It is alsoimportant not to reduce the temperature excessively, in order to preventproblems during later steps. The ideal temperature of the mass isbetween 60 and 90° C.

At this step the paste is extracted by a pump and forced into anextruder for formation of the spheroidal cores. Both the pump body andthe extruder are steam-heated to prevent seizure of the unit. At the endof the extrusion channels the paste is immediately cut into smallportions of the required length by rotating scraper blades. The paste iscut while fully immersed in a cold water stream (10-20° C.). The cutportions are shaped by the turbulence of the stream into a spheroidalshape and simultaneously cooled and sent to a separation tank where thespheroidal cores are separated by centrifugation, collected by aconveyor belt, dried and talced, while the water is cooled andrecirculated.

As the gum base is hydrophobic, the formation and cooling process doesnot cause any significant losses of flavoring or sweetener.

The flavoring could alternatively be mixed with the gum base by omittingthe second screw mixer and inserting a static mixer between the feedtank and the extruder.

The product obtained at this step is complete, and can be used as is orcoated.

A conventional coating process is used.

The very small size of the cores provides an end product in which thecoated part has a percentage weight greater than that of a standardproduct, and weighs 40% more than the total pellet. Coating may becarried out using polyols such as maltitol, isomalt, sorbitol, xylitoland the like, either alone or mixed. Maltitol and isomalt areparticularly preferred.

In view of the high percentage of coating and the polyalcohol chosen,the pellet is much crunchier than others on the market.

The example below illustrates the invention in greater detail.

Core Composition Ingredient Percentage Gum base   96% Peppermintflavoring  3.8% Acesulfame K 0.19% Neo-hesperidin DC 0.01% Total  100%

Coating Composition Ingredient Percentage Maltitol 90.25% Titaniumdioxide    4% Peppermint flavoring  1.5% Glycerin    1% Aspartame  0.2%Gum arabic    3% Carnauba wax  0.05% Total   100%

In this example, the coating constitutes 50% of the end weight of thepellet.

EXAMPLE OF CORE PRODUCTION PROCESS

1. Preparation of gum in a double-Z mixer at 115° C.

2. Transfer of mass to a screw-mixer with plough blades at 90° C.

3. Addition of flavorings and sweeteners, and stirring for 60 min.

4. Extrusion and cutting of extruded mass of flavored gum.

5. Formation of cores with water stream at 10-20° C.

6. Drying and talcing of cores.

1. A spheroidal chewing gum with a diameter below 10 mm, consisting of aflavored gum base sweetened by high-intensity sweeteners selected fromacesulfame K and/or neo-hesperidin DC.
 2. A product as claimed in claim1, further coated with a polyols or sugar coating layer.
 3. A pellet asclaimed in claim 2, wherein the polyols are selected from maltitol andisomalt.
 4. A pellet as claimed in claim 1, wherein the core containsgum base, one or more flavorings, and possibly colorings andplasticizers.
 5. A pellet as claimed in claim 1, wherein the sweetenersand/or the flavorings are encapsulated.
 6. A pellet as claimed in claim1, wherein the coating layer constitutes at least 40% by weight of thewhole pellet.
 7. A product as claimed in claim 1, wherein the gum baseis selected from those having the following composition: 8 to 15% of anelastomer selected from the group comprising polyisobutylene andisobutylene-isoprene copolymer 0 to 8% of a natural gum 8 to 20% ofresins selected from the group of vegetable and synthetic resin esters 8to 20% of polyvinyl acetate 8 to 25% of hydrogenated or partlyhydrogenated vegetable or animal oils 3 to 10% of waxes selected fromthe group comprising vegetable waxes and waxes derived from petroleum orobtained synthetically 2 to 10% of emulsifiers and processing aids,specifically glycerol monostearate, acetylated monoglycerides, lecithinsand triacetin 10 to 45% of inert mineral fillers up to 0.1% ofantioxidants.
 8. A product as claimed in claim 1, wherein the gum baseis selected from those having the following composition: synthetic gums12.6% terpene resins/rosin esters 14.3% polyvinyl acetate 14.1%hydrogenated vegetable oils 10.9% microcrystalline waxes 4.8% glycerolmonostearates 4.0% acetylated monoglycerides 0.8% lecithins 0.4% fillers38.0% antioxidants 0.1%


9. A process for the manufacture of a spheroidal chewing gum with adiameter below 10 mm, consisting of a flavored gum base sweetened byhigh-intensity sweeteners selected from acesulfame K and/orneo-hesperidin DC, which comprises the steps of: a) mixing the gum basecomponents in a mixer at the temperatures normally used; b) cooling themixture obtained in a) to a temperature of between 60 and 90° C.,possibly in a second mixer, and adding flavorings and high-intensitysweeteners under stirring; c) extruding the mass obtained in b) in aheated extruder through small-diameter holes; d) cutting the extrudedportions with rotating blades immersed in a water stream at atemperature of between 10 and 20° C.; e) separating drying and talcingor dusting the spheroidal cores obtained in d); f) possibly, coating thespheroidal cores.
 10. A process for the manufacture of a spheroidalchewing gum with a diameter below 10 mm, consisting of a flavored gumbase sweetened by high-intensity sweeteners selected from acesulfame Kand/or neo-hesperidin DC, which comprises the steps of: a) mixing thegum base components in a mixer at the temperatures normally used; b)cooling the mixture obtained in a) to a temperature of between 60 and90° C., and injecting flavorings and high-intensity sweeteners upstreamof a static mixer; c) extruding the mass obtained in b) in a heatedextruder through small-diameter holes; d) cutting the extruded portionswith rotating blades immersed in a water stream at a temperature ofbetween 10 and 20° C.; e) separating, drying and talcing or dusting thespheroidal cores obtained in d); f) possibly, coating the spheroidalcores.